InteliBifuel controllers THE PRACTICAL DUAL FUEL CONTROL MANAGEMENT SOLUTION FOR DIESEL ENGINE APPLICATIONS

Transcription

1 InteliBifuel controllers THE PRACTICAL DUAL FUEL CONTROL MANAGEMENT SOLUTION FOR DIESEL ENGINE APPLICATIONS

2 Benefits Substantial Fuel Savings & Operational costs Substitute up to 70 % of your diesel consumption with gas Reduce your operational costs substantially Case study of CAT 3512B, 1500 kva, 1500 RPM 100% $ Diesel Gas 80% $ % 100% 70% $ % $ % $ % 30% $ 0 $ Before After Before After Fuel consumption at nominal output Fuel costs per year Extended Run Times without refueling Normal run time with standard diesel tank FUEL 10 days extended run time without refueling due to 70% gas substitution rate Manufacturing & production factories On shore/off shore drilling rigs and operations Data centers Shopping complexes Municipal systems Wastewater treatment Financial institutions Healthcare facilities Other critical installations Continuous operation Prime Power applications Standby power Peak shaving & Peak saving 2 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

3 Greener Energy ComAp Bi-fuel is a more environmentally friendly solution for Diesel engines Emission reductions possible: Reduction of CO 2 5% to 20% Reduction of NO x 30% to 40% Reduction of SO x 70% to 100% Reduction of Particulate emissions (PM) up to 50% Together with the option of the fitment of a catalytic convertor, significant reduction of CO can also be expected (please enquire at bifuel.support@comap.cz). Other important benefits and features Fuel flexibility Maintenance savings longer oil life and increased periods between required maintenance intervals No de-rating of engine power output or performance ideal for transient loads Fully automatic and dynamic solution which will safely maximize the substituted gas All engine parameters are kept within the limits specified by the engine manufacturer: Engine boost air and exhaust temperatures measurement, monitoring/protection Minimum & Maximum Gas pressure measurement, monitoring/protection Comprehensive Knocking detection system Frequency sensors fitted to every cylinder (InteliBifuel 20) Diesel portion mapping and measurement Actual Load measurement Minimum Load gas protection Smooth transition between diesel and bi-fuel modes at any time Non intrusive solution no change of any engine parts required Gas/diesel ratio display Full history files recording Remote monitoring, control and configuration via PC or via the internet COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 3

4 Solution How it works The Bi-fuel principle is based on adding gas to the engine (this can be also perceived as an addition of an alternative energy e.g. the gas). Generator engines are typically governed and therefore must maintain the same RPM at all times, when an alternative energy (the gas) is introduced to the governed engine there is simply less energy (or power) required to be delivered by the engine s diesel governor. This allows InteliBifuel to control precisely the amount of gas being introduced to the engine and in doing so enable lower quantities of diesel to be used to provide the power. The diesel engine principal does not change the engine is still dieseling and the diesel fuel is required to provide 30% of the engine power, parts lubrication, cooling and as an ignition source for the gas. ComAp s quality and fully automated InteliBifuel solution ensures that all key engine safety parameters are met at all times. Should any engine parameter move towards a maximum limit, the amount of gas will automatically decrease and adjust itself and should any of the engine manufacture s parameters be exceeded for any reason, gas is immediately stopped and the engine continues to operate on 100% diesel without any interruption of the power supply. By this principle InteliBifuel achieves the highest possible gas/diesel ratio. On the next page is an example of ComAp InteliBifuel system used in paralleling gensets application. However, InteliBifuel can be configured for various applications: pumps, frac trucks, heavy mining trucks, locomotives, ships, etc. Please contact bifuel.support@comap.cz for more information. Frequently asked questions 1. How much diesel can be replaced? Depending on the type of engine typical gas/diesel ratios after conversion are up to 70% gas/30% diesel. There are additional factors which can also affect gas/diesel ratios such as: engine condition, ambient weather conditions at the site, site load variability, and gas quality etc. 2. Is my engine suitable? Yes. Any 4 stroke diesel engine is generally suitable. 3. Will Bi-fuel affect engine performance? No, the engine performance will remain the same as before the conversion. The engine can still operate up to full or maximum load at any time; it should be noted that the best gas/diesel ratios are normally achieved at around 80% of nominal engine power, which is usual for a continuous operation. When the engine needs to operate above 80% of nominal engine the ComAp InteliBifuel automatically decreases the amount of gas. Also the engine s response to load steps and transient loads or changes will remain exactly the same as before the conversion. 4. Does ComAp InteliBifuel system interfere with the existing control system on my engine? No, InteliBifuel does not interfere with the existing engine control system nor does it control the engine in any way or stop the engine at any time. InteliBifuel is mainly concerned with the precise control of the gas and protection of the engine when operating in Bi-fuel mode. Gas is only introduced to the engine once the engine has already started and is running on 100% diesel. 5. What warranty or guarantee is provided by ComAp? ComAp has a standard two year warranty for all ComAp products. 6. What types of gases can be used? ComAp InteliBifuel will safely maximize the use of any available combustible gas, i.e. natural gas, well gas, bio gas, landfill gas, propane gas, coal gas, CNG, LNG. ComAp provides a free gas suitability feedback service where you can send any gas analysis to: bifuel.support@comap.cz 4 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

5 CAN2 IL-NT GPRS InteliBifuel DENOX 20 InteliCompact NT MINT J1939 InteliBifuel CU GAS INLET GEN-SET IL-NT GPRS GAS THROTTLE VALVE SHUTOFF VALVES GAS TRAIN MainsCompact NT IL-NT GPRS InteliBifuel DENOX 20 InteliCompact NT MINT J1939 InteliBifuel CU GAS INLET GEN-SET MAINS GAS THROTTLE VALVE SHUTOFF VALVES GAS TRAIN IL-NT GPRS LOAD InteliBifuel DENOX 20 InteliCompact NT MINT J1939 InteliBifuel CU GAS INLET GEN-SET GAS THROTTLE VALVE SHUTOFF VALVES GAS TRAIN GAS KNOCKING SENSOR TURBO CHARGER AIR FILTER EXHAUST TEMPERATURE SENSOR EXHAUST AIR BOOST AIR TEMPERATURE SENSOR CAMSHAFT INTERNET REMOTE CONTROL ROOM FLYWHEEL COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 5

6 Key Elements of the system InteliBifuel CU Many types of communication Perfect price/performance ratio Built-in PLC-integrated control of technology Features The InteliBifuel CU is the highly flexible main control unit of the ComAp fully featured InteliBifuel solution. This sophisticated Bi-fuel (dual fuel) controller has outstanding monitoring, protection and control features including allocation for J1939 protocol and/or sensors that may be used in order to convert any type of diesel engine to Bifuel operation. The InteliBifuel CU protects the engine during Bifuel operation by controlling the gas throttle valve and gas shut off safety solenoid valves, preventing the engine from exceeding any critical safety parameters. This advanced controller is designed to communicate through both standard and proprietary CAN J1939 communication protocols to a wide range of EFI engines including: Caterpillar, Cummins, Detroit Diesel, Deutz, GM, Isuzu, Iveco, John Deere, MAN, MTU, Perkins, Scania, Sisu, Volvo Penta and others. Benefits Integrated solution with hardwired safety functions Full communication support of engines with ECU access to information from ECU via Modbus Event driven History recording, easy backtracking and problem solving Slave panels available economical solution for remote control Integrated clutch control less wiring and components 14 binary inputs, 14 binary outputs, 8 analog inputs RS232/Modem/Modbus/Internet communication Engine measurement from sensors or via J1939 Input/output and J1939 configuration Bifuel running hour meter Sealed membrane panel to IP65 Operating temperature: -20 to +70 C regular unit -40 to +70 C low temperature unit 3 level password protection InteliBifuel CU controller meets several forcing counter standards (EN, UL, CSA, NFPA) Configurable PLC functions Logical functions: AND, OR, XOR, RS Comparators with delay or with hysteresis Analog switch from two inputs to one output Mathematical functions: ADD, SUB, MAX, MIN, AVG Linear interpolation, moving average PID loops with analog or binary outputs Counters, Timers, Delay functions History and protection forcing Ramp Up/Down, Inc/Dec, Jump Extension modules and remote display possibilities up to 1 I-AOUT8 (Analog Outputs Extension Module) up to 4 IGS-PTM (Input/Output Module) up to 4 IS-AIN8 (Analogue Input Module) up to 3 IS-BIN16/8 (Binary Input/Output Module) up to 4 IGL-RA15 (Remote Annunciator) up to 2 I-RD-CAN (Remote Display with CAN Bus Interface) 6 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

7 InteliBifuel DENOX 2 InteliBifuel DENOX 20 Anti knocking device Field proven solution for knocking detection Integration with InteliBifuel CU controller via Analog and Binary outputs Parameters for adjustment accessible via DenEdit software 2 monitoring channels Each channel can be configured for single cylinder or for the monitoring of neighbouring cylinders Suitable for all inline engines up to a maximum of 6 cylinders Anti knocking device Field proven solution for knocking detection Integration with InteliBifuel CU controller via Analog and Binary outputs Parameters for adjustment accessible via DenEdit software Up to 20 monitoring channels Each channel can be configured for single cylinder monitoring up to 20 cylinders Suitable for engine up 20 cylinders InteliBifuel DFM Order codes Package InteliBifuel 2 InteliBifuel CU InteliBifuel DENOX 2 InteliBifuel DFM Software and documentation Order code IBF-2 Dual-Fuel Module interface unit for InteliBifuel CU controller with Speed governor and Diesel actuator Gas throttle valve servo control loop Diesel consumption measurement via current loop InteliBifuel 20 InteliBifuel CU InteliBifuel DENOX 20 InteliBifuel DFM Software and documentation IBF-20 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 7

8 References Mexico Simply Integrated Solution Ottomotores Largest genset packager in Mexico Ottomotores offers Bi-fuel range of gensets with ComAp InteliBiFuel as standard product Multiple projects carried out in 2012 with following engines: Perkins 2806, 2206; Cummins QSK60-G6, QST30-G4 Nigeria Short Payback Period Dangote Pasta Caterpillar 3512B 1200 kw gensets Short payback period less than 2 months Prime power operation Natural gas 8 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

9 Romania Oil & Gas Environment Eneria Romania Caterpillar 3512B 1200 kw gensets Remote location oil platform, Black sea Prime power operation Natural gas Russia Extreme Climatic Conditions Severo-Khosedayuskoe Energocentrum Cummins KTA50 gensets Cummins QSK60 gensets Prime power operation Natural Gas Extreme conditions COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 9

10 Examples of converted high speed engines Brand Type DG set Output Caterpillar 3300 series 150 kw 220 kw Caterpillar 3400 series 200 kw 650 kw Caterpillar 3500 series 700 kw 2000 kw Caterpillar C15 series 500 kw Caterpillar C18 series 400 kw 500 kw Caterpillar C27 series 800 kw Cummins KTA series 400 kw 1200 kw Cummins QSK series 1100 kw 1800 kw Cummins QST series 650 kw 800 kw Cummins VTA series 500 kw 600 kw Deutz TBD series all outputs MAN D2842LE kw Mercedes OM444LA/12183TB kw Mitsubishi SR6-PTA 440 kw 600 kw Mitsubishi S12R-PTA 1285 kw MTU 18V kw MTU 20V kw Perkins 2206D-13TAG3 400 kw Perkins 2306C E14 TAG1A 280 kw Perkins 2506C E15TAG3 450 kw Perkins 2806C-E18TAG3 600 kw Perkins 2806A-E18TAG2 560 kw Perkins 3012TAG2A 580 kw Perkins TAG3A 600 kw Perkins TAG kw SCANIA DC series 225 kw 520 kw Volvo TD series all outputs 10 COMAP INTELIBIFUEL THE PRACTICAL SOLUTION

11 About ComAp ComAp is a dynamic international company with a solid reputation for delivering innovative electronic solutions to the power generation, industrial engine and equipment markets. By providing customers with state-of-the-art products, ComAp has built a name for delivering excellent reliability and good value. Excellent and reliable product solutions ComAp specializes in creating electronic control and management solutions for use in the power generation industries and drive power markets. Our portfolio of products, software and accessories is designed to support emergency power, standby power generation and engine driven applications all over the world. We also work closely with our customers to develop unique customized and turn key solutions for ordinary and extraordinary applications delivering high standards of excellence on every project. Professional partnerships ComAp s extensive global distributor network means that our products are locally available in almost 100 countries, spanning every continent in the world. Through our professional and highly dedicated global distributor network we can satisfy customers needs, however challenging. People make the difference ComAp s key strengths are flexibility, experience, knowledge and enthusiasm. This blend of values defines our personality and gives you the assurance of a truly honest and positive relationship. By supporting our people, investing in their development and encouraging creativity, our teams work hard to find new opportunities, technologies and solutions that enable us to successfully help our customers solve their problems effectively. At ComAp, we believe passionately in the importance of continuously developing new technology along with forward thinking software and hardware to maintain the enviable position as worldwide leader in communication and control for power generation and drive power applications. COMAP INTELIBIFUEL THE PRACTICAL SOLUTION 11

12 ComAp create advanced control management systems for the power generation and drive power markets, achieving customer satisfaction through proven reliability and optimum flexibility with simple and intuitive operation. MANUFACTURER: LOCAL DISTRIBUTOR / PARTNER: ComAp a.s. Czech Republic Phone: Fax: info@comap.cz Internet: Customer satisfaction is our mission. We continuously develop our people to be the best to succeed in our mission. ComAp. Features and specification are subject to change without prior notice /CPBECIBC